Portable shelter



Sept. 2, 1969 F. L. RUSSELL ET AL 3,454,168

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United States Patent 3,464,168 PORTABLE SHELTER Frank L. Russell, WestLebanon, N.H., and Thomas P. Lyons, Jr., Middlehorough, Mass., assignorsto the United States of America as represented by the Secretary of theArmy Filed Nov. 3, 1967, Ser. No. 681,066 Int. Cl. E04!) 1/343, 7/10 US.CI. 5263 Claims ABSTRACT OF THE DISCLOSURE The invention describedherein may be manufactured, used, and licensed by or for the Governmentfor governmental purposes without the payment to us of any royaltythereon.

This invention relates to a completely prefabricated, lightweight,weathertight, portable shelter, which may be easily and quickly erectedat the shelter site by inexperienced personnel without special tools.

While there are presently available many different types of lightweightstructures, notably of the tent variety, which can be easily and quicklyerected on a desired site to provide a certain measure of protectionagainst the elements, such structures are not considered suitable foruse under adverse weather conditions involving high winds, heavy rain orsnow, or low temperatures. Other shelters, which are rigid rather thanflexible in nature, are able to withstand and provide protection againstextreme environmental conditions but are normally quite heavy, difiicultto assemble and erect, and occupy a great deal of space even whendisassembled. This invention, on the other hand, provides a shelter thatis lightweight, small in cube when disassembled and therefore eminentlyair-transportable; in addition, it is Weathertight, can successfullywithstand winds as high as 100 knots, wind loads of 40 p.s.f. and snowloads of 40 p.s.f., and because of the low thermal conductivity of thematerials used in its construction is suitable for use in both polar andtropical climates.

The objects and advantages of the present invention will become apparentin the following detailed description of the invention taken inconjunction with the accompanying drawings, which illustrate preferredembodiments of the invention and wherein:

FIGURE 1 is a perspective view of a structure according to the presentinvention;

FIGURE 2 is a perspective view of the structure of FIGURE 1 without theend walls and roof covering;

FIGURE 3 is a view in elevation of one end of the structure of FIGURE 1;I

FIGURE 4 is a. detail section at the joint between the floor boxes;

FIGURE 5 is a detail section of a portion of 'the roof taken on the line55 of FIGURE 1;

FIGURE 6 is a view in section taken on the line 66 of FIGURE 1; 7

FIGURE 7 is a view in section taken on the line 77 of FIGURE 1;

FIGURE 8 is a view in section taken on the line 8-8 of FIGURE 1;

3,464,168 Patented Sept. 2, 1969 FIGURE 9 is a top plan view of a roofsection.

A completely assembled building structure in accordance with the presentinvention, is shown in FIGURE 1. This structure is formed of a pluralityof interchangeable modular units which are connected to each other toform an integral structure of any desired length. Each modular unit isdesigned and constructed so that all of its individual components willbe contained within a single packing case forming a relativelylightweight, compact shipping unit. Since each modular unit contains thecomponents for one end wall, it is necessary to employ at least twounits to complete a shelter. As will become apparent hereinafter, thestructure of this invention is designed so as to be quickly and easilyerected on site by unskilled personnel using simple tools in order thata protective shelter may be quickly set up even under adverseconditions.

Since the assembled structure must be both wind and Weatherproof, it isessential that all components be rigidly locked together and gasketedwhere necessary. While any mechanical fastening means may be employed tohold together the components of the structure, it is preferred that thefastening means be both rapid and foolproof in operation. It is alsodesirable that the fastening elements be fixed to or integral with thecomponents to be joined together so as to reduce the chance of loss andto facilitate the rapid set-up of the structure. One such fasteningmeans found to be satisfactory consists of a cammed hook or key whichenters into and engages a recessed crossbar or loop within a femaleelement. Such a cam locking device offers two noteworthy advantages; itrequires but one tool, usually a hexagonal key or wrench, to accomplishthe locking or unlocking operation and the locking operation serves toprogressively draw the components together in a tight fittingrelationship. While such a locking or fastening device is used to makeall connections in the preferred embodiment of this invention andreference, hereinafter, to a locking device or fastener will beunderstood to mean such a cam locking device, it is obvious that otherlocking means may be employed in this invention. It is, however,advantageous to use one common type of locking or fastening meansthroughout the structure since such an arrangement will facilitateassembly and eliminate the need for special tools.

The various components of the structure must of necessity belightweight, of sufiicient strength to withstand the expected loads,have good insulative qualities and be tough enough to withstand therigors of assembly and use. Many materials are available which will meetthese requirements to some degree, e.g., metal or resin impregnatedglass fiber structures having foam insulation laminated thereon. Onematerial found to have excellent qualities of strength, toughness andinsulation as well as being lightweight and easy to fabrictae intocomplex shapes is a composite of glass cloth and organic foam whereinthe glass cloth forms the exterior surface of the structure and theopposing larger surfaces are connected at regular intervals by ties ofglass cloth which are either perpendicular to the faces or set at anglesto the surface. Slabs of urethane or styrene foam of appropriateconfiguration are inserted within the glass cloth pockets. The resultingflexible member is placed in a mold of suitable configuration and resinis injected under pressure to impregnate the cloth and to tie thecomponents together into a rigid unit. With this type of construction,delamination of foam insulation from the matrix is impossible. Unlessotherwise specifically indicated herein, all structural components ofthis invention are constructed of this material which is commerciallyavailable under the trade name, Raypan, manufactured by RaymondIndustries, Inc., Huntington Park, Calif.

FIGURE 1 of the drawings illustrates an assembled structure designatedgenerally as 10 which is constructed of three modular units. Theprincipal components of the structure can be seen in this view andcomprise a floor 11, laterally spaced, parallel, upright, rigid arches12 spanning the floor, roof covering sections 13 positioned between saidarches and an end wall 14 having a doorway 15, ventilator 16 andsmoke-pipe jack 17.

The three modular units comprising the structure of FIGURE 1 aredelivered to the site in three packing cases each of which contains thecomponents for a single module, such as two arches, two roof coveringsections, one end wall, and a plurality of cable sections. To save onweight and space, the packing case itself does double duty, in that italso serves as the floor for each module. The packing case isconstructed of two identical halfsections each of which, for example,measures 16 feet by 4 feet and is inches deep. As shown in FIGURE 2 andin more detail FIGURE 4, the half-sections are positioned so that thelong side walls 22 are in abutting relationship, and then securedtogether by means of mating fasteners 20 and 21. In similar fashion, thefloor sections of the different modules are secured together. The longside walls 22 double as floor joists and assure adequate support of thelong fioor span or surface 23. It has been found to be desirable to lockthe floor sections together with splines 24 to insure a wind andweatherproof joint and to increase the rigidity of the fioor surface.

After the floor has been assembled, arches 12 are set in place as shownin FIGURE 2. While a half-round arch configuration would be desirablefrom a strength standpoint, such a configuration drastically curtailsthe amount of usable space within the structure. To satisfy the twinobjectives of maximum strength and usable space, the arch configurationshown in FIGURE 3 is used. A typical arch, thus formed, is 8 feet abovethe fioor at its midpoint and consists of a 2 foot straight verticalsection as each leg of the arch surmounted by a compound curve sectionhaving a 12 foot radius extending 2230 each side of center and a 5.5foot radius are connecting the ends of the 12 foot radius arc to the topof the vertical legs. With little sacrifice in strength as compared witha simple 8 foot radius semi-circle, this configuration will permit a 6foot tall man to stand erect within 2 feet of the sidewall. In order toaccommodate the arch within the 4 x 12' package, it is formed ofidentical half sections which are subsequently releasably securedtogether at the mid-point 25 of the arch by fasteners to form the rigidarch.

In transverse section each arch has an inverted T-shape as shown inFIGURES 6 and 7 which shape functions both to stiffen the arch and toprovide a seat for the roof covering sections 13. The bottom or end ofeach arch is releasably secured by fasteners 27 and 28 to the floor endwalls 26 preferably at the joint between each floor section as depictedin FIGURE 2. Spaced radially about each arch are six openings 32 whichextend transversely through the arch and are aligned with similaropenings on other erected arches.

After the arches have been assembled and locked in place to the floor, aseparate thin steel cable 30 is drawn through each of the six sets ofopenings 32, and held in place or locked to the end arches by oversizewing nuts 31 threadably attached to either end of the cable. Theindividual openings 32 are somewhat oversize as shown in FIGURES 6 and 7so that the cable 30 may readily be drawn through. The cable is ofmodular construction and is formed of a plurality of approximately 4foot lengths of galvanized steel wire rope which is substantially equalto the space between adjacent arches. Each individual length of wirerope has female, internally threaded sleeves 33 aflixed at each endthereof. An externally threaded stud 34 with a wrench grip 35 locatedmidway between the ends thereof which constitutes means for turning sameis threadably insertable at either end within a sleeve 33 so as toconnect two lengths of wire rope. By connecting short lengths of wirerope together in this manner, wire cables 30 may be assembled ofsufficient length to extend through and tie together all of the archesin the completed structure. Oversize wingnuts 31 are threadably engagedto the end of studs 34 at each end of the cable externally of the endarches to prevent the cable from being pulled through the openings 32 inthe end arches.

Each roof covering section 13, shown in plan view in FIGURE 9, isconstructed of a plurality of rigid, block segments 36 which are affixedto a continuous waterproof cloth covering 37, e.g., rubber impregnatednylon cloth. The blocks are dimensioned to ride on the seat formed bythe inverted T of a pair of arches with the width of each block as wellas its degree of curvature being determined by the shape of the arch.When in place and resting on the arches, the blocks of each section arein abutting edge to edge relationship providing a solid covering betweeneach pair of arches. It should also be noted that when in place betweenthe arches the section is substantially rigid in a directionperpendicular to the plane of the arches. The number of blocks is notcritical but should be such as will permit folding of the roof section13 along its longitudinal axis and enclosure within the packing case. Inthe present example, there are 14 blocks in each section. Provision ismade for a cable slot or transverse channel 38 in the underside of theblock segments to accommodate the wire cable 30 spanning the arches. Thewaterproof cloth covering 37 has excess material 37 extending laterallyon either side thereof dimensionedto extend over and cover each adjacentarch. This excess of material is held in place along the opposite sideof each arch by a tensioned nylon rope 39 contained within a loop 40running along each marginal edge of the cloth covering. The ends of thenylon rope are tied down to the opposite ends of each arch. All arches,save the arch on either end of the structure, will, when the roof iscompletely in place, be covered with two overlapping layers of fabric asshown in FIGURE 6. The end arches will be covered with one layer offabric and require an additional nylon rope 41 to hold the fabric inplace about the end arch as shown in FIGURE 7.

The block segments 42 at either end of the roofing section 13 aregasketed and contain fastening means 43 which mate with fastener 44 onthe floor as shown in FIGURE 8 holding the segments 42 tightly to thefloor to ensure an air-tight joint. While the roof covering section 13has been described as being a plurality of blocks attached to anoversize cloth covering, it is not essential that there be excesslateral material on either side of the blocks or that there be a clothcovering. Since the abutting edges of the blocks are beveled so as tofit snugly together, the blocks will provide an essentially weathertightroof. The cloth covering, however, does provide an additional measure ofinsurance to ensure a weathertight covering and also facilitatesassembly of the roof.

When all the roof sections are in place, the steel cables between theend arches are shortened by threadably advancing the wing nuts at eitherend. As the cables shorten, the arches are drawn tightly against theblock segments of the roof sections, post tensioning the entirestructure and locking the block segments to the arches by compressivefriction producing a rigid, weathertight roof covering that canwithstand wind, snow and rain. The steel cables, therefore, function asadjustable tensioning means to maintain the arches and roof covering intight fitting end to end relationship to hold the roof tightly in place.

The end wall 14 of the structure shown in FIGURES 1 and 3 disposedsubstantially within the plane defined by the end arch consists of fivepanels with the central panel 48 containing the door 15 and ventilationports 16 and 17 The panels are locked together along their vertical sideedges and form an integral wall with the joints being gasketed toprovide a weathertight closure. A tongue 46 shown in FIGURE 7 extendsupwardly from the top of each panel and is adapted to be inserted andretained within a groove 47 in the arch. Gaskets 48 are located oneither side of the tongue. The bottom of the endwalls is attached orlocked to the floor by means of angle clips 49 which are fastened to thefloor side wall 22 and which extend upwardly into a groove 50 in thelower portion of the endwall. An advantage of this endwall is that itmay serve as an outside endwall or an interior partition 51 as shown inFIGURE 2. Location of any interior partition will be beneath any archwith the tongue and groove connection in the arch serving to hold thepartition in place.

It will be apparent from the foregoing description that this inventionprovides a lightweight portable, easilyerected shelter that is suitablefor use in all environments ranging from tropical to polar. The use ofmodules allows for flexibility with respect to the length of the shelterto be constructed and in the event of loss of one modular unit. Sinceeach component of each module is standardized, the use of massproduction techniques is feasible and results in substantial lowering ofcosts of the shelter. Standardization of the components and modulessimplifies the assembly of the shelter and the use of common integralfasteners also facilitates assembly. The use of steel cables to tensionthe arches against the roof 'blocks placing the latter under compressionmaterially increases the strength and rigidity of the structure.

We claim:

1. A portable building structure assembled of modular units andcomprising in combination:

(a) A floor constructed of modular components releasably fastenedtogether to form a rigid platform,

(b) A plurality of parallel, upright, spaced-apart, rigid, supportarches positioned over said floor and having the ends of each of saidarches releasably fastened to said floor, each of said arches having ashape of an inverted Tee in cross section and being formed of aplurality of sections having releasable fasteners associated therewithfor joining said sections into the arch,

(c) A roof covering comprising a plurality of roof sections, each roofsection adapted to span the space between a pair of adjacent arches andto be supported by said adjacent pair of arches, said roof sectionformed of a plurality of blocks of rigid material adapted to be heldtogether in tight fitting relationship, said blocks being attached toand covered by an external, continuous, flexible, waterproof covering,

(d) End walls disposed substantially within the plane defined by thearches at either end of the structure, and

(e) Adjustable tension means disposed between the end arches of thestructure to maintain the arches and roof covering in tight fittingrelationship end to end of the structure whereby each roof section isheld in place between the arches by compressive friction, saidadjustable tension means being a plurality of separate, horizontallydisposed cables spaced radially about said arches and having means foradjusting the length thereof, each of said cables being constructed of aplurality of cable sections having an internally threaded sleeve on eachend of said section and externally threaded studs having means forturning same located between the ends of said cable sections, said studsbeing threadably receivable in said sleeve to connect said sections ofcable into a single length, each of said sections of said cable having alength substantially equal to the space between adjacent arches of saidstructure.

2. A portable building structure according to claim 1 wherein saidarches are provided with a plurality of radially spaced aligned openingstherein, said cables passing through said openings.

3. A portable building structure according to claim 2 wherein said roofsections are provided with transverse channels in the interior surfacethereof aligned with said radially spaced openings in said arches toreceive said cables.

4. A portable building structure according to claim 3 wherein saidmodular components of said floor maybe releasably joined to form acontainerfor receiving the said sections of two complete arches, two ofsaid roof sections, one end wall, and a plurality of said cable sectionsand studs whereby the components of said building structure may bepacked in modular units for storage and transport.

5. A portable building structure according to claim 1 wherein said meansfor adjusting said cables comprises a threaded stud fixed to the endsthereof and a wing nut threadably engaged on each stud externally of theend arch.

References Cited UNITED STATES PATENTS 1,377,500 5/1921 Nissen 52-862,874,812 2/1959 Clevett 5286 X 2,877,506 3/1959 Almoslino 52-42272,896,271 7/1959 Kloote et al 5263 3,088,558 5/1963 Dickinson 52-227 X3,156,018 11/1964 Slayter 5290 X 3,280,522 10/1966 Palfey et al 52-584 XFRANK L. ABBOTT, Primary Examiner PRICE C. PAW, JR., Assistant ExaminerUS. Cl. X.R. 52--86, 227, 496

